Machining time and costs

BACHELOR OF ENGINEERINGBACHELOR OF ENGINEERING
MANUFACTURING TECHNOLOGIESMANUFACTURING TECHNOLOGIES
MACHINING TIMEMACHINING TIME
& COST ESTIMATION& COST ESTIMATION
by Endika Gandarias

2by Endika Gandarias
Dr. ENDIKA GANDARIAS MINTEGI
Mechanical and Manufacturing department
Mondragon Unibertsitatea - www.mondragon.edu
(Basque Country)
www.linkedin.com/in/endika-gandarias-mintegi-91174653
Further presentations: www.symbaloo.com/mix/manufacturingtechnology

3
CONTENTS
BIBLIOGRAPHY
INTRODUCTION
MACHINING COST ESTIMATION
MACHINING TIME
CUTTING PARAMETERS
GLOSSARY
by Endika Gandarias

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BIBLIOGRAPHY
BIBLIOGRAPHY
by Endika Gandarias

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The author would like to thank all the bibliographic references and videos that
have contributed to the elaboration of these presentations.
For bibliographic references, please refer to:
• http://www.slideshare.net/endika55/bibliography-71763364 (PDF file)
• http://www.slideshare.net/endika55/bibliography-71763366 (PPT file)
For videos, please refer to:
• www.symbaloo.com/mix/manufacturingtechnology
BIBLIOGRAPHY
by Endika Gandarias

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INTRODUCTION
INTRODUCTION
by Endika Gandarias

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INTRODUCTION
• Any product or service that aims to success in the market must fulfill
the CUSTOMER demands:
• Product / service Quality
• Product / service Cost
• Product / service Delivery Time
• Consequently, it is essential for a company to differentiate from their competitors in one or
more of these aspects:
by Endika Gandarias

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• When manufacturing a component, there is a strong relation among COST and:
• Material
• Process
• Design
• Assembly
INTRODUCTION
DFMA
Design For Manufacturing and Assembly
analysis and optimization
of these interrelations
Material
Design
Process
Assembly
COST
by Endika Gandarias

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• Thus, manufacturing department must be in close relation with all other departments in a company:
- Design dept. - Purchase dept.
- Quality dept. - Sales dept.
- Etc.
INTRODUCTION
by Endika Gandarias

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INTRODUCTION
by Endika Gandarias
Material

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INTRODUCTION
by Endika Gandarias
Process

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PROPOSED DESIGN
Looks OK,
right?
INTRODUCTION
by Endika Gandarias
Design
Assembly

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FINAL DESIGN
After DFMA
what a difference!
INTRODUCTION
by Endika Gandarias
Design
Assembly

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MACHINING COST ESTIMATION
by Endika Gandarias

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• COST ESTIMATION consists in calculating the costs of the product or/and services that a company
offers.
• Most commonly used machining COST ESTIMATION methods are:
• PRIMA (PRocess Information Maps)
• Parametric calculation  an estimation of manufacturing cost
• Analytic calculation  a more precise cost calculation method
• WHY DO WE NEED TO DO A COST ESTIMATION METHOD?
• To identify if a new product is feasible or not, and to modify it in an early design stage.
• To define the product price.
• To verify offers obtained from different suppliers  subcontracting
• To identify the most economical process to manufacture the product.
• To identify expenses and help in their minimization.
• To take strategical decissions: eliminate a product, subcontracting, discounts,…
by Endika Gandarias

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• As mentioned before, the price is defined by the market and not by our production/manufacuring cost.
• So we must always produce below the market price.
Direct cost + indirect cost + profit = product price  ideal business
Direct cost + indirect cost = product price  no profit
Direct cost + indirect cost < product price  no business
• PROS:
• It offers a very accurate estimation.
• CONS:
• It is a time consuming cost estimation method.
• A lot of data is necessary to feed the method.
ANALYTIC Cost Estimation
by Endika Gandarias

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ANALYTIC Cost Estimation
• In the ANALYTIC cost estimation, the final cost of the product is calculated by considering the real
cost of all the steps/processes.
• Each step/ process adds a value to the final product but for doing so a cost is necessary.
• The main cost that are taken into consideration are as follows:
DIRECT COST (DC)
INDIRECT COST (IC)
• Material cost
• Tooling cost
• Manufacturing cost
• Any subcontracting cost
• Commercial cost ( ~ %10 DC)
• Indirect cost ( ~ %25 DC)
DESIRED PROFIT
( ~ %15 (DC + IC))
PRODUCT TOTAL PRICE
+
+
by Endika Gandarias
Machining time
calculus is required.

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MACHINING TIME
by Endika Gandarias
MACHINING TIME

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MACHINING TIME
MACHINING TIME ESTIMATION METHODS
by Endika Gandarias
• The TOTAL MACHINING TIME (TT) calculus is very important to determine:
• Manufacturing costs: Machine rate [€/h] * TT [h]
• Machine work loads
• Personnel needs.
• Delivery time
• The cutting time (TCUTTING) is the only one that can be accurately calculated.
Rest of the times need to be estimated.
• Most commonly used TIME ESTIMATION methods are:
1. By estimation.
2. By comparison.
3. By timing.
4. By the sum of elementary predefined times.

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MACHINING TIME
• Time necessary to prepare the machine-tool to be
ready to start machining:
• Workholding device set-up
• Toolholding device set-up
• Material procurement
• Tool procurement
��−�� : Set-up time �MANUAL OPERATION : Manual operation time
• It is difficult to calculate properly because it varies depending
on part’s dimensions and weight, machine tool, etc.
• In general, manual operation time > cutting time.
• Workpiece clamping and un-clamping
• Non-cutting movements
• Tool changes
• Taking references
• Measurements
�CUTTING : Cutting time �UNFORESEEN : Unforeseen time
• It is the time consumed in movements that remove
material.
• Non-cutting movements, such as fast approximations
or retracts, are not considered.
L: tool or workpiece
displacement.
V: displacement speed.
• It covers all the time gone in unforeseeable events during the
machining process (unexpected times).
• Machine-tool breakdown.
• Tool wear or breakage
• Lack of raw material.
• Blackout
by Endika Gandarias

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MACHINING TIME
• It consists in breaking down the operation in different smaller phases, so that a rough estimation can
be made based on the experience of the technicians.
• It is commonly used when:
• unitary parts or small batches are required.
• not enough data is available.
• delivery time is short.
• As it is a estimation method, it is not very accurate.
BASED ON THE TECHNICIAN EXPERIENCE
By estimation
by Endika Gandarias

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• It consists in determining the time of a specific operation by comparing it with the time consumed a
previously machined similar operation.
• As it is a estimation method, it is not very accurate.
However, it is more accurate than the estimation method.
BASED ON OTHER PARTS EXPERIENCE
MACHINING TIME
By comparison
by Endika Gandarias

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MACHINING TIME
BASED ON THE TIMING
1ª OPERACIÓN
HABLAR
Los operarios antes de comenzar el proceso comentan entre ellos sobre el
trabajo que habrán de desempeñar
DURACIÓN= 30 Seg.
2ª OPERACIÓN
¿Qué haremos
ahora? Bueno, empezaremos a
preparar la máquina
LISTADO DE OPERACIONES
TIEMPO TOTAL = 38 MIN 50 SEG
OPERACIÓN TIEMPO
1 Hablar 0 min 30 seg
2 Limpiar 1 min 20 seg
3 Traer los elementos 0 min 40 seg
4 Parar la prensa y limpiar los bajos de la estampa 0 min 40 seg
5 Limpiar la trasera de la prensa 2 min 00 seg
6 Ir en busca de la maza y del cabezal 0 min 34 seg
7 Extraer la cuña 3 min 24 seg
8 Colocar los rodillos y extraer el molde 1 min 15 seg
9 Coger la grúa y enganchar 1 min 10 seg
10 Trasladar la estampa vieja 0 min 45 seg
11 Traer la estampa nueva 1min 00 seg
12 Llevar los elementos 0 min 15 seg
13 Atar la prensa nueva 3 min 00 seg
14 Retirar los rodillos elementos y devolverlos 1 min 15 seg
15 Ajustar la estampa para meter bien la chapa 2 min 30 seg
16 Ir a por la cuña y volver 0 min 21 seg
17 Hablar con el encargado 0 min 30 seg
18 Meter la cuña 0 min 40 seg
19 Atar las bridas delanteras y traseras 1 min 52 seg
20 Regular en altura 0 min 12 seg
21 Embridar la parte delantera y trasera 0 min 52 seg
22 Tocar con el tope la altura 0 min 55 seg
23 Apretar 0 min 20 seg
24 Revisar la carrera 4 min 20 seg
25 Hacer pruebas 2 min 00 seg
26 Aguardar la 1ª pieza 1 min 00 seg
27 Primera prueba 0 min 30 seg
29 Segunda prueba 0 min 20 seg
30 Comprobar si está bien 0 min 20 seg
31 Apretar todo adecuadamente 2 min 20 seg
• It consists in measuring the time needed to manufacture
the part.
• Thus, it is a very time consuming and expensive method.
• It is commonly used when:
• Very stable & automatized processes are required.
• Large series are required.
LISTADO DE OPERACIONES
TIEMPO TOTAL = 38 MIN 50 SEG
OPERACIÓN TIEMPO
1 Hablar 0 min 30 seg
2 Limpiar 1 min 20 seg
3 Traer los elementos 0 min 40 seg
4 Parar la prensa y limpiar los bajos de la estampa 0 min 40 seg
5 Limpiar la trasera de la prensa 2 min 00 seg
6 Ir en busca de la maza y del cabezal 0 min 34 seg
7 Extraer la cuña 3 min 24 seg
8 Colocar los rodillos y extraer el molde 1 min 15 seg
9 Coger la grúa y enganchar 1 min 10 seg
10 Trasladar la estampa vieja 0 min 45 seg
11 Traer la estampa nueva 1min 00 seg
12 Llevar los elementos 0 min 15 seg
13 Atar la prensa nueva 3 min 00 seg
14 Retirar los rodillos elementos y devolverlos 1 min 15 seg
15 Ajustar la estampa para meter bien la chapa 2 min 30 seg
16 Ir a por la cuña y volver 0 min 21 seg
17 Hablar con el encargado 0 min 30 seg
18 Meter la cuña 0 min 40 seg
19 Atar las bridas delanteras y traseras 1 min 52 seg
20 Regular en altura 0 min 12 seg
21 Embridar la parte delantera y trasera 0 min 52 seg
22 Tocar con el tope la altura 0 min 55 seg
23 Apretar 0 min 20 seg
24 Revisar la carrera 4 min 20 seg
25 Hacer pruebas 2 min 00 seg
27 Primera prueba 0 min 30 seg
29 Segunda prueba 0 min 20 seg
30 Comprobar si está bien 0 min 20 seg
31 Apretar todo adecuadamente 2 min 20 seg
By timing
by Endika Gandarias

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MACHINING TIME
• It consists in breaking down the execution of a part in elementary phases. The time needed to be
accomplish these elementary phases are predefined in tables (machine notebooks).
• It is commonly used when a fast and economic decision need to be taken.
• It is an accurate time estimation method.
By the sum of elementary predefined times
Technical specifications Predefined elementary times
by Endika Gandarias

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MACHINING TIME
TURNING MILLING
PERIPHERAL OR
SIDE MILLING
TURNING FACING FACE MILLING
CUTTING TIME CALCULUS (��)
DRILLING
by Endika Gandarias

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MACHINING TIME
TURNING - Turning
C
P
ϕ
ϕ
L c
P
by Endika Gandarias

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Calculate the cutting time needed to finish turning a Ø60 mm steel part down to Ø59.6 mm in a
length of 60 mm if a tungsten carbide tool main positioning angle of 45º is used.
The cutting speed is 120 m/min, the cutting depth 0.2mm, the feed per revolution 0.2 mm/rev and
the safety distance 2 mm.
SOLUTION: TCUTTING = 0,49 min
MACHINING TIME
TURNING - Turning
by Endika Gandarias

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A part of Ø60 mm is aimed to be achieved after making successive rough turning operations
and starting from an aluminium bar of Ø75 mm. The tool is made of High Speed Steel and the
tool main positioning angle is 60º.
If a cutting speed of 40 m/min, a feed per revolution of 0.25 mm/rev, a cutting length of 120 mm
and a cutting depth of 1.5 mm is used, calculate the machining time considering an entry and
exit security distance of 2mm.
MACHINING TIME
TURNING - Turning
by Endika Gandarias

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MACHINING TIME
TURNING - Facing
C
R ϕ
L
•
r
C
P
ϕ
by Endika Gandarias
r = tool nose radius

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The finish facing of a steel part of Ø300 mm is aimed to be machined in a lathe at a constant spindle
speed.
Calculate the cutting time spent on the operation knowing that the HSS tool main positioning angle is
60°, the tool nose radius is 0.8 mm and the entry security distance is 2mm.
For additional cutting data, please refer to “Cutting parameters” section at the end of this presentation.
MACHINING TIME
TURNING - Facing
by Endika Gandarias

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An aluminium part of Ø300 mm and a length of 150 mm will be machined using a rough facing operation
in a lathe using a constant spindle speed, and its length is aimed to be shortened to 140 mm.
Calculate the cutting time spent on the operation knowing that the main HSS tool positioning angle is
60°, the tool nose radius is 0.8mm and the entry security distance is 2mm.
MACHINING TIME
TURNING - Facing
by Endika Gandarias

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MACHINING TIME
MILLING – Peripheral or side milling
by Endika Gandarias
L
L
L

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MACHINING TIME
MILLING – Face milling
by Endika Gandarias
L
L
L

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MACHINING TIME
MILLING – Face milling
It is aimed to machine a steel flat surface using a face milling tool. The surface to be machined is 100
mm wide by 300 mm length.
Determine the cutting time knowing that a finishing operation will be accomplished in a single cutting
depth, the carbide tool diameter has 12 teeth and a Ø = 150 mm. The entry and exit security distance
are 3mm.
by Endika Gandarias

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MACHINING TIME
DRILLING
H 2
H
c
r
by Endika Gandarias
L
L
=
==
L
nn
V
L
T
a
c
........................................................................................
...................................................·
l
c
L

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MACHINING TIME
DRILLING
Determine the cutting time needed to drill the steel part of the
figure, knowing that a rough operation will be carried out using
a twist drill with a tip angle of H=118°. The entry and exit
security distance are 3mm.
For additional cutting data, please refer to “Cutting
parameters” section at the end of this presentation.
by Endika Gandarias

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CUTTING PARAMETERS
by Endika Gandarias
CUTTING PARAMETERS

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CUTTING PARAMETERS
VARIABLE UNIT DESCRIPTION
HOW TO
CALCULATE?
TURNING MILLING DRILLING
Vc m/min Cutting speed TABLES
N rpm or rev/min Spindle speed N=(Vc*1000)/(π*Ø)
fz mm/tooth*rev Feed per tooth TABLES
fn mm/rev
Feed per
revolution
TABLES
fn = fz * z
F mm/min
Feed rate or
feed per minute
F = fn * N
Ap mm
Axial cutting
depth
TABLES
Tool radius
Ae mm
Radial cutting
depth
TABLES
Parameter introduced into the machine.
Parameter NOT introduced into the machine.
SUMMARY TABLE
by Endika Gandarias

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MACHINE
WORKPIECE
MATERIAL
TOOL MATERIAL OPERATION
Vc
(m/min)
fn
(mm/rev)
Ap
(mm)
TURNING
MACHINE
STEEL
HIGH SPEED STEEL
(HSS)
Turning and facing
D 30 – 40
A 40 - 50
D 0.1– 0.25
A 0.02/ 0.1
D 0.75-2
A 0.2-0.8
Parting and grooving 10 – 15 0.02 – 0.1
Threading 10 Thread pitch According to formula
Drilling 18 Manual
Knurling 10
Boring
D 20 – 30
A 30 - 40
D 0.1– 0.25
A 0.02/ 0.1
D 0.75-2
A 0.2-0.8
HARD METAL
Turning and facing
D 80 – 100
A 100 - 120
D 0.1– 0.25
A 0.02/ 0.1
D 0.75-2
A 0.2-0.8
Threading 40 - 50 Thread pitch According to formula
Drilling 30 – 40 Manual
Boring
D 70 – 90
A 90 - 110
D 0.1– 0.25
A 0.02/ 0.1
D 0.75-2
A 0.2-0.8
ALUMINIUM
HIGH SPEED STEEL
(HSS)
Turning and facing
D 40 – 60
A 60 - 80
D 0.1– 0.25
A 0.02/ 0.1
D 0.75-2
A 0.2-0.8
Threading 15 Thread pitch According to formula
Drilling 30 Manual
Knurling 20
Boring
D 30 – 50
A 50 - 70
D 0.1– 0.25
A 0.02/ 0.1
D 0.75-2
A 0.2-0.8
HARD METAL
Turning and facing
D 150 – 180
A 180 – 200
D 0.1– 0.25
A 0.02/ 0.1
D 0.75-2
A 0.2-0.8
Parting and grooving 80– 100 0.04 – 0.1
Threading 50 – 60 Thread pitch According to formula
Drilling 60 – 80 Manual
Boring
D 140 – 170
A 170 - 190
D 0.1– 0.25
A 0.02/ 0.1
D 0.75-2
A 0.2-0.8
by Endika Gandarias
D: Roughing operation
A: Finishing operation
CUTTING PARAMETERS: TURNING

MACHINE
WORKPIECE
MATERIAL
Vc
(m/min)
fz
(mm/tooth*rev)
Ap
(mm)
Ae
(mm)
MILLING
MACHINE
STEEL
HIGH SPEED
STEEL
(HSS)
Face milling
D 20 - 25
A 25 - 30
0.05 – 0.1
0.01 – 0.05
D 1-2
A 0.2-0.5
D (~2/3)Ø
A (~2/3)Ø
Side milling
D 20 - 25
A 25 - 30
0.05 – 0.1
0.01 – 0.05
D (50%-80%)Ø
A (50%-80%)Ø
D (10%-25%)Ø
A (5%-10%)Ø
Other milling
D 15 - 20
A 20 - 25
0.05 – 0.1
0.01 – 0.05
HARD METAL
Face milling
D 80 - 100
A 100 – 120
0.05 – 0.1
0.01 – 0.05
D 1-2
A 0.2-0.5
D (~2/3)Ø
A (~2/3)Ø
Side milling
D 80 - 100
A 100 – 120
0.05 – 0.1
0.01 – 0.05
D (50%-80%)Ø
A (50%-80%)Ø
D (10%-25%)Ø
A (5%-10%)Ø
Other milling
D 70 - 90
A 90 – 100
0.05 – 0.1
0.01 – 0.05
ALUMINIUM
HIGH SPEED
STEEL
(HSS)
Face milling
D 50 - 70
A 70 - 90
0.05 – 0.1
0.01 – 0.05
D 1-2
A 0.2-0.5
D (~2/3)Ø
A (~2/3)Ø
Side milling
D 50 - 70
A 70 - 90
0.05 – 0.1
0.01 – 0.05
D (50%-80%)Ø
A (50%-80%)Ø
D (10%-25%)Ø
A (5%-10%)Ø
Other milling
D 40 - 60
A 60 - 70
0.05 – 0.1
0.01 – 0.05
HARD METAL
Face milling
D120 - 150
A 150 – 180
0.05 – 0.1
0.01 – 0.05
D 1-2
A 0.2-0.5
D (~2/3)Ø
A (~2/3)Ø
Side milling
D120 - 150
A 150 – 180
0.05 – 0.1
0.01 – 0.05
D (50%-80%)Ø
A (50%-80%)Ø
D (10%-25%)Ø
A (5%-10%)Ø
Other milling
D100 - 130
A 130 – 150
0.05 – 0.1
0.01 – 0.05
Other milling: slot milling, t-shape milling, dovetail milling, form milling.
D: Roughing operation
A: Finishing operation
CUTTING PARAMETERS: MILLING

MACHINE
WORKPIECE
MATERIAL
Vc
(m/min)
fn
(mm/rev)
DRILLING
MACHINE
STEEL
HIGH SPEED STEEL
(HSS)
Spot drilling 18 0.04 – 0.1
Drilling 18 0.04 – 0.1
Counterboring 9
Countersinking 9
ALUMINIUM
HIGH SPEED STEEL
(HSS)
Spot drilling 30 – 40 0.04 – 0.1
Drilling 30 – 40 0.04 – 0.1
Counterboring 15 – 20
Countersinking 15 – 20
CUTTING PARAMETERS: DRILLING
ROUGHING FINISHING
Vc
fn


fz


F
ap
ae

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GLOSSARY
GLOSSARY
by Endika Gandarias

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GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Aim Pretender / Aspirar a Asmoa izan
Alloy Aleación Aleazio
Assembly Ensamblaje Muntaia
Axial cutting depth Profundidad de pasada axial Sakontze sakonera
Bar Barra Baraila
Batch Lote Sorta
Blackout Apagón eléctrico Itzalaldi
Boring Mandrinado Mandrinaketa
Brass Latón Letoi
Breakage Rotura Matxura
Breakdown Rotura Matxura
Business Negocio Negozio
Cat iron Fundición / Hierro fundido Burdinurtu / Fundizio
Copper Cobre Kobre
Counterboring Lamado Lamaketa
Countersinking Avellanado Abeilanatu
Customer Cliente Bezero
Cutting speed Velocidad de corte Ebaketa abiadura
Dealership Franquicia Frankizia
Delivery Entrega Emate
Dovetail Cola de milano Mirubuztan
Drilling Taladrado Zulaketa
Expense Gasto Gastu
Face milling Planeado Lauketa
Facing Refrentado Aurpegiketa
Feasible Viable Bideragarri
Feed per revolution Avance por vuelta Aitzinamendua birako
Feed per tooth Avance por diente Aitzinamendua hortzeko

45
GLOSSARY
by Endika Gandarias
Feed rate Avance por minuto Aitzinamendua minutuko
Finishing Acabado Akabera
Foil Lámina / Hoja / Papel Xafla mehe / Orri
Glass Vidrio Beira
Gray cast iron Fundición gris Burdiurtu grisa
Grinding Rectificado Artezketa
Grooving Ranurado Artekaketa
Hard metal Metal duro Metal gogorra
High Speed Steel (HSS) Acero rápido Altzairu lasterra
Ingot Lingote Lingote
Knurling Moleteado Moletaketa
Lathe Torno Tornua
Lowercase Minúscula Letra xehe
Manufacture Fabricación Fabrikazio
Nose radius Radio de punta Muturreko erradioa
Parting Tronzado Trontzaketa
Pitch Paso Neurri
Planing Cepillado Arrabotaketa
Powder Polvo Hauts
Procurement Adquisición / Compra Erosketa
Profit Beneficio Onura
Purchase Compra Erosketa
Radial cutting depth Profundidad de pasada radial / ancho de pasada Iraganaldi zabalera
Rate Tasa Tasa
Raw Bruto Landugabe
Reaming Escariado Otxabuketa
Rod Barra calibrada Baraila kalibratua
Rough Basto Trauskil

46
GLOSSARY
by Endika Gandarias
Roughing Desbaste Arbastaketa
Rubber Goma / Caucho Goma / Kautxu
Sale Venta Salmenta
Scope Especificaciones Zehaztapen
Set-up Puesta a punto Doikuntza
Shape Forma Itxura
Shaping Limado Karrakatze
Sheet Lámina Xafla
Slot milling Ranurado Artekaketa
Spindle speed Velocidad de giro Biraketa abiadura
Spot drilling Punteado Punteaketa
Stage Etapa Etapa
Stainless Steel Acero inoxidable Altzairu erdoilgaitz
Steel Acero Altzairu
Supplier Proveedor Hornitzaile
Teeth Dientes Hortzak
Threading Roscado Hariztaketa
Timing Cronometraje Kronometraje
Toolhonding device Sistema de amarrar herramientas Erramintak lotzeko sistemak
Tubing Tubo Tutu
Tungsten carbide Carburo de tungsteno Tungsteno karburoa
Turning Torneado Torneaketa
Twist drill Broca helicoidal Barauts helikoidala
Unforeseen Imprevisto Aurreikusi gabeko
Wear Desgaste Higadura
Weight Peso Pisu
Wire Alambre Burdin hari
Workholding device Sistema de amarrar piezas Piezak lotzeko sistemak

47
GLOSSARY
by Endika Gandarias
Wrought Worked Landua

Machining time and costs

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